Method and apparatus for placing wire coils with varied lengths on dynamo electric motor stators

ABSTRACT

An apparatus for forming varied length wire coils for insertion into stator core slots includes a template positioned that is configured to vary a length of consecutive wire turns while wire is received from a flyer winder. The wire turns may then be inserted into a pair of stator core slots depending upon their respective lengths. A method of using the apparatus to form a winding with varied length turns includes depositing wire turns on a template, varying a length of at least two consecutive wire turns as the wire is deposited on the template, removing the wire turns from the template, and inserting the removed wire turns into stator core slots.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This is a continuation of application Ser. No. 09/590,532, filedJun. 8, 2000 (which is hereby incorporated by reference herein in itsentirety), which claims the benefit of U.S. provisional application No.60/139,157, filed Jun. 14, 1999, and No. 60/141,158, filed Jun. 25,1999.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to solutions for winding coils ofstators that are used in induction motors. More particularly, theinvention relates to winding wire coils with turns that have differentlengths and inserting the completed coils into stator core slots.

[0003] Electric motors generally include two main parts—a fixed hollowportion known as a “stator” and a portion that rotates inside thestator, called a “rotor” or an “armature.” Electrically conducting coilsof wire are typically wound in longitudinal slots on the stator. Rotorsare configured in many different ways, but they are also wound withelectrically conducting wire. Current supplied to the rotor wiresinteracts with a magnetic field that is produced in the stator to createthe torque that is required to operate the motor.

[0004] Wire coils are typically formed by winding wire around a pair ofthe longitudinal slots described above. Sections of the wire coilstypically span across the end of the stator where they exit one slot andenter the other. Filling the slot with wire generally requires placingsome turns deeper inside the slot (i.e., further away from the centralaxis of the stator core) than others. In the most common windingmethods, all turns of wire in the coil are formed with approximately thesame length of wire. The length of wire that is used during winding isthat which is required to form the longest turns—those that will beplaced furthest away from the axis of the core. As a result, the turnsthat are placed closer to the central axis usually have more wire thanthey need to be routed through the portions of the slot where they rest.This means that there is more slack in those turns that are placedcloser to the center of the core than there is in those that are moredeeply inserted.

[0005] At least one existing device is capable of forming wire coilswith turns that have different lengths. An apparatus that may accomplishsuch a task has been described in U.S. Pat. No. 6,206,052, the contentsof which are hereby incorporated by reference in their entirety. In sucha device, wire is wound around a template while its sections are movedtoward or away from each other in a direction orthogonal to thelongitudinal axis of the template. Moving the template sections apartduring winding forms a larger wire turn, while moving them togetherforms a smaller wire turn.

[0006] The present invention proposes new solutions for forming coilturns with varied lengths and for placing completed coils that are madefrom such turns into stator core slots. In one embodiment, the relativepositioning of the sections of a template are altered as wire is woundaround the template. As described earlier, altering template positioningduring winding enables the turns to be formed with different lengths.These varied length turns are gathered to make the completed coils.

[0007] According to an aspect of the invention, wire turns are depositedon an insertion tool in an order that is dependent upon the lengtharound the longitudinal slot pair at the depths at which it is desiredto place the turns. More specifically, wire turns will be deposited onthe insertion tool in an order that is dependent upon their respectivelengths. These respective lengths will, in turn, be dependent upon thedistance around the slot at the depth at which it is intended to placethe turn. The turns are placed between rods that are positioned to matchpredetermined angular locations of the stator slots, and the completedcoils are pushed along the rods and into the appropriate pair of slotson the stator core.

[0008] The present invention can be used to form a coil with variedlength turns, and to position the turns in each coil such that they restat the depth inside the slot that is most appropriate for their lengths.Turns will preferably rest at the location inside the slot that will usesubstantially the entire length of the wire turn in routing the wirebetween the slots and around the stator core. Tension in each wire willpreferably be optimized. That is, the amount of tension in each wirewill preferably be high enough to form turns without slack, while beinglow enough to avoid pulling and stretching the wire.

SUMMARY OF THE INVENTION

[0009] Objects of the invention include eliminating excessive wireconsumption, efficiently filling stator core slots, and achievingoptimal wire tension in completed coils. An embodiment of the inventionachieves these objects by providing apparatus for winding stator coreslots with wire coils that have varied lengths, characterized in that itincludes a template positioned to receive wire from a winder. Thetemplate is configured to vary a length of at least two consecutive wireturns as it receives the wire. An insertion tool is also provided. Theinsertion tool collects the wire turns in an order that is dependentupon their respective lengths, and maintains the turns in this collectedorder.

[0010] Another embodiment of the invention includes a method of windingstator core slots with wire coils that have varied lengths, thatincludes the steps of varying a length of at least two consecutive wireturns as the wire turns are formed on the template, delivering theconsecutive varied length wire turns to an insertion tool in an orderthat is dependent upon their respective lengths, collecting thedelivered wire turns to form a coil and maintaining the wire coil in thecollected order. The wire coil is subsequently inserted into a pair ofstator core slots.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A preferred embodiment of the invention will now be describedwith reference to the annexed drawings, given purely by way ofnon-limiting example, in which:

[0012]FIG. 1 shows an end view of a stator core with slots that havebeen wound with a traditional coil;

[0013]FIG. 2 is an end view of a stator core wound according to theprinciples of this invention;

[0014]FIG. 3 is a schematic elevation view of a template, winder andinsertion tool according to an aspect of the invention;

[0015]FIG. 3A is a detailed view of the inclined surface of a stepillustrated in FIG. 3;

[0016]FIG. 4 is a plan view of a traditionally formed coil placed in astandard insertion tool;

[0017]FIG. 5 is a elevation view of the coil and insertion toolillustrated in FIG. 4;

[0018]FIG. 6 is a plan view of a coil and insertion tool according toprinciples of the present invention;

[0019]FIG. 7 is an elevation view of the coil and insertion toolillustrated in FIG. 6;

[0020]FIG. 8 is a plan view of a transfer tool of the present invention;

[0021]FIG. 9 is a plan view of a transfer tool joined to an insertiontool according to an aspect of the invention;

[0022]FIG. 10 is an elevation view of an end effector which can be usedto form leads according to an aspect of the invention, shown from thesame view as that of FIG. 7;

[0023]FIG. 11 is a view of the end effector of FIG. 10 shown from thedirection indicated by arrows A;

[0024]FIG. 12 is a detailed view of a coil constraint that may be usedin accordance with the invention;

[0025]FIG. 13 is a plan view of an exemplary embodiment of a templatewith several sections upon which coils can be formed according to theinvention; and

[0026]FIG. 14 is an elevation view of another embodiment of a templatethat may be used according to the invention.

DETAILED DESCRIPTION

[0027] The present invention relates to solutions for winding coils ofstators, and particularly to forming wire coils that have differentlengths. Such coils will preferably be inserted into pairs oflongitudinal slots that are present in stator cores.

[0028] The ideal length for a wire turn that will be wound on a statorcore is a function of how deeply the turn should rest inside the pair ofslots into which it will be inserted. Turns with different lengths maybe formed by winding wire around a template whose diameter can be variedduring winding. One way to vary the diameter of a template is to alterthe relative positioning of sections from which it is formed. Templatesections are typically moved apart during winding to form a larger wireturn and moved closer together during winding to form a smaller turn.

[0029] According to the invention, as a coil is formed, its individualturns are transferred from the template to an insertion tool.Significantly, wire turns are transferred to the insertion tool in anorder that is dependent upon their lengths, which is generally afunction of how deeply they will be inserted into a pair of longitudinalslots on a stator core. When a device such as that described above isused, wire turns that are formed first are usually the shortest, andthey will typically be transferred to the insertion tool first. Thesecond formed turn that is slightly longer will be formed next, andconsecutively formed turns that gradually get longer as winding proceedsare formed in succession. The wire turns are inserted in the slots inthe reverse order of the way they are delivered to the insertion tool.Thus, when the smallest coils rest on the bottom and the largest coilsrest on the top, the largest coils will be inserted into the slots firstand the smallest will be inserted last. This produces wire coils withthe largest turns resting in the deepest portions of the slots and thesmallest turns resting nearest the central axis of the core.

[0030] An insertion tool preferably has rods which are positioned tomatch predetermined angular positions of the slots in the stator wherethe finished coils will be placed. The tool is transported to the statorand its rods are aligned with the stator core slots. The turns of thecoil are then pushed along the rods and inserted into the designatedslots.

[0031] Referring now to the drawings which are provided to describeexemplary embodiments of the invention and not for limiting same, FIG. 1shows an end view of a stator core 10 with slots 12 and 14 that holdconstant length wire turns. For sake of clarity, only the externalportion of two turns T1 and T2 of the traditional coil are illustratedhere. Those skilled in the art will recognize that a finished coil willtypically have many more than two turns, and that the end of a stator 10will usually not appear exactly as shown here when a full coil has beeninserted into slots 12 and 14.

[0032] Turns T1 and T2 span across the end of stator core 10, and restinside slots 12 and 14. When a coil has been inserted into slots 12 and14, turn T1 rests deeper inside each slot (i.e., further away from thecentral axis O of the stator core), than does turn T2. Again, all turnsT1 and T2 of the coil have been formed with approximately the samelength of wire. This wire length is just sufficient for routing thoseturns such as T1 which rest deepest inside the slots. Thus, the lengthof turn T1 exceeds that which is needed to form the turns like T2 whichrest closer to the central axis of the stator. As shown, when constantlength wire turns are provided, turns T2 will typically havesignificantly more slack than turns T1.

[0033] The present invention proposes methods and apparatus for formingcoil turns T1 and T2 with lengths that are dependent upon the depthinside slots 12 and 14 at which it is desired to place them. Under suchcircumstances, each of the wire turns will be just long enough to berouted through the designated pair of slots and around stator core 10with a minimal amount of slack. While as much slack should be eliminatedas is possible, it is also important to avoid placing too much tensionon the wire. The turns are preferably placed inside the slot indescending size order to place the longest turns deepest into the slots.This allows a large volume of wire to fit in the available slot space.

[0034] Turning now to FIG. 2, an end view of a stator core wound usingthe method and apparatus of the present invention is illustrated. TurnsT1 and T2 span across the end face of the stator core 10 as in FIG. 1.However in FIG. 2, turn T2 is formed with wire that has a shorter lengthand less slack than turn T1. Note that unlike turn T2 of FIG. 1, neitherturn contains a significant amount of slack.

[0035] Referring now to FIG. 3, in accordance with the invention, thelengths of wire turns 28 are gradually varied as flyer 20 rotates aroundtemplate 30. This creates long turns which can be placed furthest intoslots 12 and 14 as well as progressively shorter turns that can beplaced closer to the central axis O of stator core 10. In the embodimentof the invention illustrated here, template 30 has four steps 32, 34, 36and 38, and two sections 33 and 35 whose relative positioning can bealtered by varying distance d between them.

[0036] This relative positioning will often, but not always, be alteredby moving the sections of template 30 in a direction orthogonal to thelongitudinal axis of the template, either toward or away from eachother. As those skilled in the art will recognize, sections 33 and 35could also be subjected to angular displacements in order to vary thesize of wire turns 28. It is intended to embrace all such alternativeembodiments of the invention.

[0037] In the preferred embodiment of the invention the outsideperimeter of template sections 33 and 35 will be inclined slightlytowards the central axis Y of the template as indicated in FIG. 3A. Thiswill assist completed turns 28 in falling from template 30 and towardsinsertion tool 40. As they descend, turns 28 will be deposited betweenrods 42 of insertion tool 40 which are aligned just below template 30.

[0038] An inward incline of the template steps 32, 34, 36 and 38 willalso help to prevent the wire from becoming over tensioned as templatesections 33 and 35 are separated. The ideal angle of this incline isdependent on the characteristics of the wire that is being delivered totemplate 30 (i.e., gauge, material, etc.) and the manner in whichseparation distance d is controlled (i.e., changed after a given numberof turns are formed on each step, or after a designated length of wirehas been delivered, etc.).

[0039] While the invention could be practiced using a template 30 suchas that illustrated in FIG. 3, it could also be practiced using othertypes of templates. For example, template 30 may have more than twosections as shown in FIG. 13, or it may be formed from two or moresections that do not have steps, but whose relative positioning may bealtered as illustrated in FIG. 14.

[0040] Turning back to FIG. 3, as flyer 20 rotates, wire 22 may bedelivered to any of template steps 32, 34, 36 or 38, but will preferablybe delivered to bottom step 32 first. The sizes of template steps 32,34, 36 and 38 will preferably correspond to sizes of coils 24 that willbe placed inside the slots 12 and 14 of stator core 10. Coil size willtypically be changed by delivering wire 22 to a smaller or larger step,while the size of the turns within a given coil will be varied byexpanding the diameter of template 30 during winding. Steps are usually,but not necessarily, wound in succession to form the desired coils. Inthe illustration, a coil is being formed on the step indicated withreference numeral 34. Previously formed wire turns 28 fall from step 34toward insertion tool 40 for placement between the designated rods 42.

[0041] Rods 42 may be located at various distances from each other. Rods42 that will be selected to receive a given coil will preferably be apair that has dimensions that correspond to those of the coil. In otherwords, rods 42 that are used to support a completed coil 24 willpreferably be those that are spaced apart by an amount that correspondsto the diameter of the coil that they will support. It should be notedhere while only one coil is shown being formed on step 34, multiplecoils will typically be formed on each step and placed on insertion tool40. The winder will then be aligned with another step, and several coilswill be formed on it and placed on insertion tool 40. FIG. 3 shows onecoil for clarity of the drawings only.

[0042] With continued reference to FIG. 3, wire turns 28 that areremoved from template 30 ride down rods 42 of insertion tool 40 to coilsupport 16. While the use of rods is preferred, it should be noted thatother types of guides may be used to transport wire turns 28 fromtemplate 30 to coil support 16. As wire turns 28 fall to coil support16, they are held by constraints 44. These constraints 44 are shaped tocause individual wire turns 28 to stack on top of each other in theorder they are delivered to insertion tool 40.

[0043] More specifically, constraints 44 collect wire turns 28 andmaintain them in an order that will cause longer turns to be placeddeeply into the slots, and shorter turns to be placed toward the centerof the slot. In the preferred embodiment of the invention, the wireturns will be collected to place the longest turn in the deepestposition in the slots, and consecutively shorter turns in positionsinside the slots that are progressively closer to the central axis ofthe core. The invention is described here with a single wire turn 28being placed at each depth within slots 12 and 14. However as apractical matter, several wire turns with substantially the same lengthswill be collected at the same depth. Then a set of smaller wire turnswith substantially the same lengths will be placed at an adjacent depthinside the slots that is slightly closer to the axis of the core. Thispattern typically repeats itself, with consecutively smaller collectionsof wire turns 28 being placed at gradually decreasing depths insideslots 12 and 14.

[0044] Collecting wire turns in the desired order preferably includesstacking subsequently placed wire turns 28 in individual layers on topof those turns that have been stacked before it. Each individual layerpreferably includes only one turn, and the turns are preferablycollected in sets that have different lengths. As best illustrated inFIGS. 6 and 7, this typically results in wire turns that are aligned onthree sides of the coil and that extend freely on one side in thepreferred embodiment of the invention. In this embodiment, wire turns 28lay on top of each other with the shortest turns resting at the bottomof the stack.

[0045] More specifically, wire turns 28 preferably includedistinguishable portions according to an aspect of the invention. Asbest illustrated in FIG. 6, in the preferred embodiment of the inventioncomplete wire turns 28 have a substantially rectangular shape, with adistinguishable top, bottom and two sides. While wire turns 28 are shownhaving a rectangular shape, those skilled in the art will recognize thatthe invention could be adapted to form other shapes, depending upon theshape of template 30. As is also indicated in FIG. 6, at least one ofthe distinguishable portions of each wire turn 28 extends freely toaccommodate their varied lengths. Other portions of wire turns 28, shownhere as the top and bottom portions, are constrained. Constraining oneor more of the distinguishable portions of wire turns 28 maintains themin the desired length dependent order.

[0046] According to the invention, wire turns 28 are delivered toinsertion tool 40 without disturbing the length dependent order that hasbeen achieved. Turning back to FIG. 3, in the illustrated embodiment ofthe invention, wire turns 28 are being delivered to insertion tool 40 inthe order in which they are formed. The shortest turn is formed firstand is delivered to the insertion tool first, and progressively longerturns are formed in succession and are delivered to the insertion toolin consecutive order. Template sections 33 and 35 are preferably movedapart gradually during winding to form successively longer wire turns28. When the turns are inserted into the slots, the coil will have itslongest turns at the outermost portion and its shortest turns near thecentral axis of the stator core.

[0047]FIG. 4 contains a top view illustrating how a coil that has beenformed with constant length wire turns 28 would appear placed betweentwo rods 42 on an insertion tool. Because all wire turns 28 have thesame length, the turns at the free end 26 of coil 24 would be bundledwithin a narrow thickness t_(c). When viewed from the side, free end 26would be substantially vertical, as illustrated in FIG. 5. Again, thisis because all the turns have substantially the same length.

[0048] Referring again to FIG. 6, coil 24 that has been formed with wireturns 28 with varied lengths is shown placed between the same two rods42 of insertion tool 40 that were shown in FIG. 4. However here, outcomeof stacking the wire turns based upon their length is apparent. Asshown, wire turns at free end 26 take up a much wider thickness t_(v)because the wire turns have different lengths. Referring again to FIG. 7a side view of coil 24 of FIG. 6 also illustrates that coil turns 28 arenot vertically aligned at free end 26.

[0049] As already discussed, insertion tool 40 has rods 42 for receivingcoils 24. Constraints 44 on coil support 16 collect wire turns 28 andmaintain them in the order they are delivered to insertion tool 40.Turning for a moment to FIG. 12, in one embodiment of the invention,coil constraint 44 includes a channel 48 with a width that is dependentupon the gauge of the wire that will be inserted into the stator slots.An opening 46 is located at the end of the channel to guide the wireinto the channel. Moveable pusher 56 may optionally be provided andmoved in the downward direction A to assist further in packing the turnstightly inside channel 48. Wire turns 28 may be removed from template 30and are transported down rods 42 toward coil support 16. As the wireturns approach constraint 44, they are drawn into channel 48 throughopening 46. The narrow width of channel 48 prevents individual wireturns 28 from bundling, and instead forces them to stack on top of eachother, and thereby maintain their proper order. While coil constraint 44as illustrated here may successfully be used, numerous other coilconstraints may also be used to practice the invention and the inventionis not limited to this embodiment.

[0050] Under most circumstances, template sections 33 and 35 will bemoved apart (i.e., distance d will be increased) as winding takes placeto increase the size of later formed turns. Because turns that areformed later during the winding process typically fall to insertion tool40 after the earlier formed shorter turns, finished coils most oftenappear as shown in FIGS. 6 and 7. However, for certain wire and coilsizes (i.e., relatively thin wire or wire turns that form coils withvery small diameters), it can be difficult to avoid over tensioning thewire. For this reason, one embodiment of the invention includes windingthe larger wire turns first and decreasing distance d as subsequentturns 28 are formed.

[0051] In such a case, if previously described embodiments of theinvention are practiced, the longer wire turns 28 will descend fromtemplate 30 before the shorter wire turns. Wire turns delivered to aninsertion tool such as that shown in FIGS. 6 and 7 would form coils inwhich the shorter turns are deposited on top of the longer turns. Thisis undesirable since the shorter turns are likely to fall inside of thelonger turns and cause the wire coil to become tangled.

[0052] Thus, when over tensioning is a concern (or when there is anyother reason to form larger turns before forming the smaller turns) itis preferable to use a transfer tool 50 such as that illustrated in FIG.8 to allow the wire turns to be inverted before they reach insertiontool 40 to place the shortest turns at the bottom of the coil. Likeinsertion tool 40, transfer tool 50 stacks and maintains wire turns 28in an order that is dependent upon their length, which is preferably theorder in which they were received from template 30. Transfer tool 50typically has multiple arrays of rods 52 and 54 to rotate coils 24 intotheir proper position. In the preferred embodiment of the invention, twoconcentrically arranged arrays of rods are provided as shown.

[0053] The rod arrays are configured such that wire turns 28 will berouted around the rods 52 and 54 that correspond to rods 42 on insertiontool 40 that will properly insert the completed coil 24 in slots 12 and14. This routing of turns 28 around rods 52 and 54, and subsequentplacement of coil 24 on insertion tool 40 should take place withoutdisturbing the stacking order or shape of wire turns 28.

[0054] Once coil 24 (configured with its largest turns at the bottom)has been placed on transfer tool 50, an insertion tool 40 may be turnedover and placed on top of it. One way to join insertion tool 40 andtransfer tool 50 is to place an array of rods 42 between arrays of rods52 and 54, as illustrated in FIG. 9. The base of transfer tool 50 willpreferably face the base of insertion tool 40 when the two tools arejoined.

[0055] In one embodiment of the invention, insertion tool 40 andtransfer tool 50 are rotated while they are still joined in order toinvert coil 24. A support plate 76 similar to coil support 16 willpreferably be applied to coil 24 opposite coil support 16 while thisinversion takes place. Once the joined insertion and transfer tools havebeen rotated, the shorter turns 28 rest on insertion tool 40 at thebottom of coil 24. The presence of support plate 76 during rotation ofthe tools and transfer of the coil to insertion tool 24 assists inmaintaining the wire turns 28 in their length dependent order. Supportplate 76 can then be removed and the two tools then be separated toleave the coil resting on insertion tool 40, configured with the largerturns 28 at the top as was the case in the embodiment of the inventionillustrated in FIGS. 6 and 7.

[0056] Turning back to FIG. 3, various functions can be used to set themagnitude of the distance between template sections 33 and 35 and/or therate at which that distance is varied during winding by flyer 20. In oneembodiment of the invention, the distance between template sections 33and 35 is varied based upon which turn 28 in coil 24 is being wound andof the position of flyer 20 as that turn 28 is being formed. Forexample, the system may be set up such that d will be varied by adesignated amount when the flyer is at an angle θ with respect to somereference point during formation of turn number n in coil 24. In anotherembodiment, the distance is varied for a designated amount of time afterturn x has been formed until turn y is formed.

[0057] The speed at which template sections 33 and 35 are moved apartwill typically be dependent upon the characteristics of the wire beingused to form coil 24. One of the most significant characteristics is thestrength of the wire, and more specifically, the ability of the wire toresist weakening as tension is applied to it. Thus when a coil 24 isformed using a thick wire, d may usually be increased at a faster ratethan when a coil 24 is formed using a thinner wire.

[0058] Still other parameters may be used to vary distance d. Forexample, template halves 33 and 35 may be moved apart when a designatedlength of wire has been delivered to the template. Devices that measuresuch parameters may be placed at numerous points along the path betweenthe template and flyer or at some other location.

[0059] In one embodiment of the invention, template sections 33 and 35are moved away from and toward each other using a controlled motordrive. In such an embodiment, wire tension readers and/or wire lengthconsumption readers can be dispersed along the path between the wiresource and flyer 20. A wire length consumption reader may be used toprovide feedback, almost instantaneously, of the length of wire that isbeing used during winding. Readers such as these are described in U.S.Pat. Nos. 5,383,619, 5,628,472, and 5,664,735, the contents of which arehereby incorporated by reference in their entirety. Feedback about wirelength consumption, tension or another relevant parameter can be used ina servo loop for the controlled motor drive, in order to more accuratelycontrol the separation distance between the template halves, and therate at which it varies.

[0060] Referring for a moment to FIG. 2, while wire turns that areclosest to the central axis of stator core 10 will usually be theshortest with successive turns 28 becoming progressively longer atfurther distances from the center of the core, other scenarios arepossible. For example, if a slot 12 or 14 is wider at the depths thatare furthest from and nearest to the central axis of the stator core,yet very narrow between these extremes, wire turns in the center of coil24 may be the shortest. If the width of the slot varies in other ways,the lengths of wire turns 28 will be varied accordingly.

[0061] The description thus far has described the invention withreference to winding and inserting a single coil 24 into a pair of slots12 and 14 of stator core 10. Those skilled in the art will recognizethat actual winding of a stator core 10 will usually require sequentialwinding of coils 24 of different sizes, and placement of these differentsized coils 24 on insertion tool 40 around rods 42 that are spaced bydifferent amounts—distances that correspond to appropriate coil diametersizes. Coils 24 will be inserted into stator core 10 as described. Thoseskilled in the art will also recognize that the principles of theinvention that have been explained to form one coil can be applied toform each of the other coils. The same support plate 16 can be used forcoils 24 that have different sizes, and constraints can be shiftedcloser to or away from rods 42 to suit the various coil sizes whichdescend from the template 30.

[0062] Leads of the coils can be formed in any of the many ways known inthe art. One such way has been described in U.S. provisional patentapplication No. 60/124,226, filed Mar. 12, 1999, the contents of whichare hereby incorporated by reference in their entirety, and in U.S.patent application Ser. No. 09/522,228, filed Mar. 9, 2000, the contentsof which are hereby incorporated by reference in their entirety.

[0063] While leads may be formed in many ways, it is important to notethat the wire turn formation that has been developed using the presentinvention must not be disturbed while this takes place. Referring againto FIGS. 6 and 7, an initial lead 56 of coil 24 will preferably beanchored at two points, both of which lie outside coil 24. In theembodiment of the invention illustrated, lead 56 is anchored inconnector block 58. However as those skilled in the art will recognize,lead 56 can be anchored at two points outside of the coil in otherdevices and in other ways, or it could be anchored at only one point orat more than two points. One way to anchor lead 56, for example, is touse a termination robot. Regardless of how the lead is anchored, slackshould be present in the portion of the wire that lies between lead 56and the size ordered turns 28 of coil 24 as shown in the illustration.

[0064]FIGS. 10 and 11 provide one example of the manner in which leads56 can be connected according to an aspect of the invention. In thisillustrated example, an end effector 60 includes two wire grippers 62for maintaining a segment S of lead 56 without leaving slack in thewire. Again, it should be noted here that the sized ordered formation ofturns 28 in coil 24 should not be disturbed as segment S is tightenedand maintained. Each wire gripper 62 preferably includes two oppositepliers 64 for gripping the lead. In one embodiment of the inventionsegment S is inserted within clamping portions 66 of connector block 58.Connector block 58 is also provided with V shaped entries 68 to alignsegment S with clamping portions 66. Insertion blade 70 (moveable in thedirection of arrow B) is also provided for moving segment S deeply intoclamping portions 66. Cutting blades 72 (moveable in the direction ofarrow C) are provided on to cut the lead of the wire at the end thatexits flyer 20. Loose end 74 of lead 56 is actually attached to coil 24in insertion tool 40 as shown in FIG. 7.

[0065] Naturally, while the principles of the invention remain the same,the details of construction and the embodiments may widely vary withrespect to what has been described and illustrated purely by way ofexample, without departing from the scope of the present invention.

The invention claimed is:
 1. Wire engaging apparatus comprising: firstand second wire engaging structures configured to releasably engage awire at respective first and second locations that are spaced from oneanother along the wire, each of the structures preventing the wire frommoving lengthwise relative to that structure when engaged by thatstructure.
 2. The apparatus defined in claim 1 wherein the first andsecond structures are spaced from one another along the wire to leave asegment of the wire between the structures that is not engaged by thestructures.
 3. The apparatus defined in claim 2 further comprising: apusher structure disposed between the first and second structures andconfigured to push the segment transverse to a longitudinal axis of thesegment.
 4. The apparatus defined in claim 2 wherein the first andsecond structures are positioned relative to one another so that thesegment extends substantially straight between the first and secondstructures.
 5. The apparatus defined in claim 2 wherein the first andsecond structures are positioned relative to one another so that thesegment can be made taut between the first and second structures.
 6. Theapparatus defined in claim 1 wherein at least one of the first andsecond structures comprises: first and second jaw members that areselectively movable toward and away from one another in a direction thatis transverse to a longitudinal axis of the wire.
 7. The apparatusdefined in claim 6 wherein when the jaw members are moved away from oneanother, the jaw members can receive the wire between them withoutdisturbance of the wire.
 8. The apparatus defined in claim 7 whereinwhen the jaw members are moved toward one another after the wire hasbeen received between them, the jaw members grip the wire between them.9. The apparatus defined in claim 6 wherein the other of the first andsecond structures comprises: third and fourth jaw members that areselectively movable toward and away from one another in a direction thatis transverse to a longitudinal axis of the wire.
 10. Wire leadmanipulating apparatus comprising: first and second wire grippingstructures configured to releasably grip a wire at respective first andsecond locations that are spaced from one another along the wire, eachof the structures preventing motion of the wire relative to thatstructure when the wire is gripped by that structure, and the structuresleaving between them a segment of the wire that is not gripped by thestructures when the wire is gripped by the structures.
 11. The apparatusdefined in claim 10 further comprising: tooling configured to push thesegment transverse to a longitudinal axis of the segment.
 12. Theapparatus defined in claim 11 wherein the tooling is further configuredto push the segment substantially perpendicular to a longitudinal axisof the segment.
 13. The apparatus defined in claim 10 wherein the firstand second structures are further configured to maintain the segmentsubstantially straight between them.
 14. The apparatus defined in claim10 wherein the first and second structures are further configured tomaintain the segment substantially taut between them.
 15. The apparatusdefined in claim 10 wherein the first structure comprises: first andsecond jaw members that are selectively movable toward and away from oneanother in a direction that is transverse to a longitudinal axis of thewire.
 16. The apparatus defined in claim 15 wherein the jaw members aremovable away from one another at least far enough to admit the wirebetween them substantially without disturbing the wire.
 17. Theapparatus defined in claim 16 wherein when the jaw members are movedtoward one another after the wire has been admitted between them, thejaw members clamp the wire between them.
 18. The apparatus defined inclaim 15 wherein the second structure comprises: third and fourth jawmembers that are selectively movable toward and away from one another ina direction that is transverse to a longitudinal axis of the wire.